Fluid manifold for a welder

ABSTRACT

A fluid manifold usable with a welder and air compressor combination. The manifold is constructed of a single unitary manifold block and which is divided into two separate fluid communication systems that are isolated from each other by the manifold block itself. Each of the separate fluid communications systems provides various channels and external ports to access those fluid channels to enable the welder and air compressor combination to be more easily assembled and constructed by locating the manifold in a convenient location within the welder and air compressor combination and which has the necessary fluid channels and conduits already formed within the manifold so that the manufacturer or assembler can simply affix the proper fluid lines and system components to the manifold in carrying out the construction of the welder and air compressor combination and be assured that the proper fluid communication will be achieved.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of, and claims priority to, U.S.application Ser. No. 10/064,344, filed Jul. 3, 2002 now U.S. Pat. No.6,883,540.

BACKGROUND OF THE INVENTION

The present invention relates generally to combined welder andcompressor units, and more particularly to a unit of this type having amanifold that is provided in order to facilitate the construction of thewelder unit by readily enabling the connection of various fluid lines.

Portable welding and compressor units transportable to a work site areknown. Typical known units include a lightweight frame consisting ofmetal tubing on which is mounted an internal combustion engine that isdirectly connected to a generator which generates an amperage to operatethe unit or welder. The generator further provides auxiliary alternatingcurrent for operating auxiliary equipment, such as an air compressor.The air compressor provides compressed air for pneumatic equipment aswell as certain welding applications, such as operating a plasma cuttingtorch. Other known portable welder and compressor units include anengine, alternator, compressor, and air tank assembly mounted within ahousing along an extended length of the housing.

In such welder and air compressor units, there are, of necessity, aconsiderable number of components that are utilized, some of which areused to channel the main compressed air from the air compressor todesired locations and others that are used to monitor the condition ofthe compressed air in order to carry out certain operations or tomonitor and/or control certain functions of the welder compressor unititself. In the normal channels of commerce, many of such components aresupplied separately and it is up to the constructor of the combinationunit to assemble and provide fluid communication for each of suchcomponents in an manner that minimizes the time and material of suchconstruction.

As such, one of the difficulties in constructing or assembling acompact, readily transportable welder compressor unit, is ininterconnecting a large myriad of fluid conduits of differing sizes andpurposes so as to make the overall welder compressor combination uniteasier to assembly and to locate many of the various fluid conduits in asingle, convenient location rather than have individual connectionsspread throughout the combination unit. Not only is the assembly timereduced but the overall unit is easier to service since many of theconnections needed for servicing the combination unit are convenientlyat one location.

Therefore, one of the main goals in the construction of a welder aircompressor combination unit is in facilitating the assembly and mountingof the various components and to make the fluid connections between suchcomponents as simple as possible and preferably centrally andconveniently located to facilitate that construction so as to simplifythe servicing of such units and to make the combination welder aircompressor compact so as to be readily transportable from one locationto another location.

BRIEF DESCRIPTION OF THE INVENTION

The present invention is directed to an improved fluid manifold that isparticularly adapted to be used with a welder and air compressorcombination to facilitate the connection of the numerous fluid conduitsneeded for the various components used with such combination unit.

In the preferred embodiment, and as will be specifically describedherein, the present manifold will be described and illustrated as beingused with a welder and air compressor combination, however, it willbecome clear that the present manifold may be used with a wide varietyof other apparatus and equipment to carry out its function of providinga convenient and central location for making certain of the fluidconnections needed in the welder air compressor combination unit.

Thus, with the present invention, a manifold is provided that comprisesa single unitary manifold block and which is divided into two separatefluid communication systems that are isolated from each other by themanifold block itself. Each of the separate fluid communications systemscarries out the task of providing various channels and external ports toaccess those fluid channels to enable the welder and air compressorcombination to be more easily assembled and constructed by locating themanifold in a convenient location within the welder and air compressorcombination and which has the necessary fluid channels and conduitsalready formed within the manifold so that the manufacturer or assemblercan simply affix the proper fluid lines to the manifold in carrying outthe construction of the welder and air compressor combination and beassured that the proper fluid communication will be achieved.

In accordance with the preferred aspect of the present invention, anengine-driven welder and air compressor combination is disclosed andincludes a compressor that provides a stream of compressed air ladenwith oil. An oil separator is provided mounted adjacent to the welderand air compressor combination and receives the oil laden stream ofcompressed air from the air compressor and separates that oil ladenstream into an pressurized air stream and a separated oil source. Acoalescing filter receives the compressed air from the oil separator andremoves further of that oil from that stream of air. The compressed aircan be used for some pneumatic equipment use and the separated oil canthen be collected and reused as a lubricant and cooling medium withinthe combination. A manifold is provided that includes a first fluidcommunication system to channel the compressed air from the oilseparator to a conduit leading into the coalescing filter and a secondfluid communication system to channel the return flow of compressed airfrom the coalescing filter to an outlet in the manifold to becommunicated, ultimately, to the pneumatic equipment.

In accordance with yet another aspect of the present invention, awelding and air compressor combination includes a manifold thatcomprises a unitary manifold block such that the fluid in the firstfluid communication system and the fluid in the second fluidcommunication system are fluidly separated from each other. In addition,the manifold of the present invention has a number of auxiliary portsfor mounting various components that are used in the control andfunctioning of the overall welder and air compressor combination.

Various other features, objects and advantages of the present inventionwill be made apparent from the following detailed description and thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplatedfor carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of a welder and air compressor combinationincorporating the present invention;

FIG. 2 is a perspective view of a portion of the welder and aircompressor combination with a housing cover removed;

FIG. 3 is a side view of the welder and air compressor combination ofFIG. 2;

FIG. 4 is a perspective view of the fluid manifold constructed inaccordance with the present invention;

FIG. 5 is a schematic view of the present manifold showing the variousports and internal passageway within the manifold;

FIG. 6 is a side, cross sectional view of the manifold of the presentinvention;

FIG. 7 is a lateral cross sectional view of the manifold taken along theline 7-7 of FIG. 6;

FIG. 8 is a lateral side cross sectional view taken along the line 8-8of FIG. 6;

FIG. 9 is a lateral side cross sectional view taken along the line 9-9of FIG. 6; and

FIG. 10 is a schematic view of the welder and air compressor combinationoil and compressed air system showing the manifold of the presentinvention used therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a portable engine-driven welder and aircompressor combination or system 10 is provided and, for brevity, willhereinafter be sometimes referred to as the welder combination 10. Thewelder combination 10 has an outer housing 12 that has one or more airvents 14 for cooling internal components of the welder combination 10.The housing 12 can be easily removed to permit access to the internalcomponents for maintenance and service. A plurality of support members16 provide stabilization for the welder combination 10 when placed on agenerally level surface, such as surface 18. An upper surface 20 of thewelder combination 10 includes a lifting hook 22 extending therethroughfor lifting and transporting of the welder combination 10. Also attachedto the upper surface 20 is an exhaust system 24 that lowers noise andremoves exhaust gas from the welder combination 10.

The welder combination 10 includes a control panel 26 that has variouscontrol elements and gauges for operating the welder combination 10. Aplurality of gauges 28 measure various parameters of the weldercombination 10. Measured parameters can include oil pressure, fuellevel, oil temperature, battery amperage, air pressure, and enginerunning time of the welder combination 10. Control panel 26 also has acontrol dial 30 and an ampere range switch 32 which are used to select avoltage/amperage for welding operations. Process selector switch 34selects the type of weld output. The weld output is determined by thetype of welding process. Examples of weld processes that may beimplemented include stick welding, TIG welding, air-carbon arc cutting,and various wire feed processes. Electrical outlets 36 provide power forelectrically driven devices, such as saws, drills, etc. Control panel 26also includes a compressor on/off switch 31 and an engine control switch33 to independently control the compressor and engine, respectively.

The control panel 26 also includes multiple power connections such as asingle phase power connect 38, an optional three-phase power connect 40,and weld-power receptacles 42. An optional polarity switch 44 can beused to select the polarity of the weld output. Typical selectionsinclude direct current electrode negative, direct current electrodepositive, and alternating current. A panel remote switch 46 and remotereceptacle 48 select remote control of the welder combination 10 ininstances where welding operations are remotely located from the weldercombination 10. Positive 50 and negative 52 battery charge connectionsare used for battery jumpstart or charging, and are positioned adjacentto a system output or shut-off valve 54. Upon engaging of the compressorclutch and opening of valve 54, compressed air is supplied for airassisted carbon arc cutting or to air driven power tools and otherpneumatic operations.

Referring now to FIG. 2, a perspective view of a portion 56 of thewelder combination 10 of FIG. 1 is shown with the housing cover 12removed. An internal combustion engine 58 is mounted to a frame assembly64 between a radiator shroud 60 and a lifting eye support member 62. Theengine 58, in a preferred embodiment, is oil cooled and configured torecirculate engine cooling oil. The lifting eye support member 62secures to the frame assembly 64 for structural support during liftingof the welder combination 10. The frame assembly 64 has air vents 14that permit air flow through the welder combination 10 to cool theinternal components. Cross-brace 66 provides structural support for theframe assembly 64. An electrical generator 67 configured to generate anarc welding current is mounted within the housing 12 of the weldercombination 10 and driven by the engine 58. The welder combinationfurther includes a screw air compressor 68 mounted to the engine 58 thatis configured to provide compressed air to the shut-off valve 54 ofFIG. 1. The screw air compressor 68 is fluidly connected to an oilseparator 70, a coalescing filter 72, which combine to separate oil froman air/oil mixture and a first particle oil filter.

The internal combustion engine 58 of the welder combination 10 includesan air intake connected to an intake manifold and engine head 78. Theengine head 78 is mounted to an engine block 80, which collectively formthe engine 58. A pulley arrangement 82 is bolted to both the engine head78 and the engine block 80 and includes a fan blade hub 84 rotated by afirst drive belt 86, such as a serpentine belt. The first drive belt 86further connects to an alternator pulley 88 that drives an alternator 90by a first crankshaft pulley 92. A belt tensioner 94 connects to amounting bracket to maintain tension on a second drive belt 96 thatdrives the screw air compressor 68 driven by a second crankshaft pulley108.

Referring now to FIG. 3, a side view of the portion 56 of FIG. 2 isshown. Frame assembly 64 connects to support member 62 which is attachedto lifting eye 22. The internal combustion engine 58 is shown having fanblade hub 84 attached to the engine head 78 as previously discussed withreference to FIG. 2. A fan (not shown) is attached to fan blade hub 84that is housed in the radiator shroud 60. Engine block 80 has alternator90 mounted thereto which is driven by the first drive belt 86. Theelectrical generator 67 mounts to the engine block 80 and is rotated bythe engine 58 to generate the arc welding current used in weldingoperations. Oil separator 70 is mounted to the frame assembly 64 with amounting plate 98. An oil return line 100 of the oil separator 70connects the oil separator 70 to other equipment, such as a radiator andultimately back to the air compressor 68 (FIGS. 1-3) for cooling andlubrication thereof.

FIG. 4 is a perspective view of the manifold 110 that is used with thepresent invention and is shown along with oil separator 70 andcoalescing filter 72. In this Figure, the oil separator 70 receives astream of compressed air laden with oil from the air compressor 68(FIGS. 1-3) through an inlet (not shown). That stream of compressed airladen with oil passes through the oil separator 70 where the air,separated therefrom is discharged through an oil separator outlet 112and enters the manifold 110 through a first main inlet port (not shown)in the manifold 110. The oil that is separated from the stream ofcompressed air laden with oil is, in turn, discharged downwardly fromthe oil separator 70 to the oil return line 100. The oil separator 70 isaffixed firmly in position to the welder combination 10 by means of themounting plate 98.

Continuing with the flow of the compressed air, it enters the manifold110 via the first main inlet (not shown) of the manifold 110 and ischanneled through the manifold 110 through a first main passageway andinto a first main outlet (not shown) in the manifold 110 and thereafterenters a first fluid conduit 114 where the compressed air, now havingmost of the oil removed therefrom, flows into an inlet 116 in thecoalescing filter 72 where a filter media removes additional oil fromthat stream of compressed air.

The stream of compressed air that is discharged through an outlet (notshown) in the coalescing filter 72 passes through a second fluid conduit118, where it returns to a second main inlet (not shown) in the manifold110. That stream of compressed air further travels through the manifold110 through a second main passageway and is discharged from manifold 110through a minimum pressure valve 120 to an outlet 122 where the streamof compressed air is thereafter communicated to an outlet or otherdevice for supplying the compressed air to an end use device, such aspneumatic equipment. The minimum pressure valve 120 maintains a minimumair pressure at the compressor outlet port to assure adequate oil flowfor lubrication and cooling of the compressor.

As further shown in FIG. 4, other components are effectively andefficiently affixed to the manifold 110 including a safety relief valve124 that is set at some predetermined pressure in excess of the normalpressure conditions of the overall pressure system of the weldercombination 10 so that the pressure will be relieved in the event thatthe pressure exceeds that set value. The pressure relief valve isaffixed directly to the manifold 110 by means of an auxiliary port (notshown) and communicates with the flow of the compressed air that passesthrough the first main passageway in the manifold 110 by means of anauxiliary port that will be later explained.

Other components that are used with the present manifold 110 include apressure gauge sender unit 126 that senses the pressure in the firstmain passageway in the manifold 110 and provide a electrical signal to aremote pressure display that is indicative of the pressure within thefirst main passageway. As a further component, there is a minimumpressure switch 128 that also senses the pressure of the fluid flowingwithin the first main passageway of the manifold 110 and prevents thecompressor clutch from engaging if the system pressure is above a presetvalue. This protects the clutch from excessive wear. With each of thecomponents of the pressure gauge sender unit 126 and the minimumpressure switch 128 there is an auxiliary port formed in the manifold110, however, both of those components may be combined so as to beoperative from one auxiliary port rather than two as shown in theembodiment of FIG. 4.

There is also a bleed down valve 130 affixed to a further auxiliary portformed in the manifold 110 and which communicates with the second mainpassageway in the manifold 110 and also a pressure feedback sensor 132that is also provided that communicates with an air intake controller tocontrol the intake air pressures, that is, if the air present in thesystem rises, the pressure feedback sensor 132 acts to shut down in theintake air to the air compressor 68 (FIGS. 1-3) and conversely, as theair pressure in the system drops, the pressure feedback sensor 132 makesan adjustment to admit more air into the air compressor 68. Again thatcomponent, the pressure feedback sensor 132 also communicates with thesecond main passageway in the manifold 110.

Turning now to FIG. 5, taken along with FIG. 4, there is shown aschematic view of the manifold 110 constructed in accordance with thepresent invention and, as can be seen, the manifold 110 is a generallyelongated unitary manifold block 134 having a longitudinal axis, a firstend 136 and a second end 138, for purposes of explaining the invention,and having a number of bores made therein to carry out the purposes ofthis invention. As can be seen, the unitary manifold block 134 is asingle, unitary, piece of material, preferably metal, and all of thepassageways and bores, and ports hereinafter to be described are formedin that unitary piece of material.

For purposes of explaining the present invention, the differing surfaceswill be referred to as the front surface 140, rear surface 142, topsurface 144 and bottom surface 146, however it will be seen that thevarious ports and functions of the present manifold 110 can be carriedout without having the ports in certain specified surfaces of themanifold 110.

Accordingly in FIG. 5, the first main inlet port 148 is shown and whichis formed by a blind bore cut into the bottom surface 146 of the unitarymanifold block 134, that is, when the first main inlet port 148 isformed, the bore does not pass fully through the manifold block 134. Assuch, therefore, the first main inlet port 148 is, in the preferredembodiment, a pipe thread port with a diameter of about ¾ inches so asto receive the male threaded outlet 112 from the oil separator 70 (FIG.4) and is formed at generally a right angle with respect to thelongitudinal axis of the elongated manifold block 134. As such, thefluid coupling between the manifold 110 and the oil separator 70 iseasily accomplished and is convenient to be carried out in theconstruction of the welder combination 10.

In a similar manner, a bore is made in the rear surface 142 of theunitary manifold block 134 to fonn a first main outlet port 150 suchthat, in the preferred embodiment, the longitudinal axis of the firstmain inlet port 148 and the longitudinal axis of the first main outletport 150 are spaced about 90 degrees apart in the unitary manifold block134. Again it is preferred that the first main outlet port 150 be a ¾inch pipe thread female connection. A first main passageway 152 isprovided to allow fluid communication between the first main inlet port148 and the first main outlet port 150 so that the fluid entering thefirst main inlet port 148 from the oil separator 70 (FIG. 4) can passdirectly to the first main outlet port 150 in accordance with theexplained flow path of the flow streams given with respect to FIG. 4.

Accordingly, there can be seen that there is a first fluid communicationsystem that is provided in the first end 136 of the unitary manifoldblock 134 that establishes a fluid path from the first main inlet port148 to the first main outlet port 150 through the first main passageway152. In addition, there may be at least one additional auxiliary portformed in the first fluid communication system located at the first end136 of the unitary manifold block 134. One of such auxiliary ports isshown as first auxiliary port 154 that is formed along the longitudinalaxis of the unitary manifold block 134 in the first end 136 thereof andis oriented generally along the longitudinal axis of the elongatedunitary manifold block 134. A second auxiliary port 156 is also formedin the first end 136 of the manifold block 134 and which alsocommunicates with the first fluid communication system, that is, secondauxiliary port 156 sees the pressure within the first main passageway152. The second auxiliary port 156 is preferably formed in the frontsurface 140 of the manifold block 134 and is sized to be a ⅛ the inchpipe thread so that the pressure gauge sender unit 126 can be easily andreadily affixed to the manifold 110.

As an option, the may also be another auxiliary port, shown as a thirdauxiliary port 158 that is also formed in the front surface 140 of themanifold block 134 and which is also preferably a ⅛ inch pipe thread andwhich communicates with the first main passageway 152 and can be used tolocate and affix the minimum pressure switch 128 therein. In a preferredembodiment, however, the third auxiliary port 158 can be eliminated anda tee (not shown) can be used with the second auxiliary port 156 so thatboth the pressure gauge sender unit 126 and the minimum pressure switch128 can both be operated from the second auxiliary port 156, in whichcase, the third auxiliary port 158 can, obviously, be eliminated andthus results in a manifold block 134 requiring less operations in itsconstruction.

In any event, as can now be seen with respect to the first end 136 ofthe manifold block 134, the are a number of ports that all arepreferably provided with female pipe thread fitting so that the desiredcomponents and conduits can easily be affixed to the manifold 110 andthe correct fluid communication immediately established, thus theconstruction of the welder combination 10 is simpler to assemble and themanifold 110 allows the correct fluid communication to be automaticallyestablished by the making of simple, easy to install, connections withthe various components. As such, the present manifold 110 can carry outconsiderable of centrally located connections that would otherwise haveto be made in a myriad of locations throughout the welder combination 10and some of which could end up in relatively inaccessible and difficultto reach locations and make the construction, as well as the latermaintenance of the welder combination 10, quite difficult.

Taking next, the second end 138 of the manifold block 134, there isformed a second fluid communication system and which comprises a secondmain inlet port 160 and a second main outlet port 162 and which can beconstructed by a straight bore formed straight through the manifoldblock 134 such that the second main inlet port 160 and the second mainoutlet port 162 are coaxially aligned, each of which are ¾ inch femalepipe threads. As such, the second main inlet port 160 opens outwardly inthe bottom surface 146 of the manifold block 134 and the second mainoutlet port 162 is formed in the top surface 144 of the manifold block134. Accordingly, the second fluid conduit 118 that channels thecompressed air from the coalescing filter 72 is connected to themanifold 110 at the second main inlet port 160 where the compressed airpasses through the manifold 110 through a second main passageway 164 tothe second main outlet port 162 that, in turn, has the minimum pressurevalve 120 affixed thereto. Preferably the second main inlet port 160 andthe second main outlet port 162 are ¾ inch female pipe thread fittings.

As with the first fluid communication system, there is at least oneauxiliary port formed in the second fluid communication system and afirst auxiliary port 166 is formed in the bottom surface 146 of themanifold block 134 and is, preferably, a ¼ inch pipe thread femalefitting. The longitudinal axis of the first auxiliary port 166 is,therefore, parallel to the longitudinal axis of the second mainpassageway 164 formed in the first end 136 of the manifold block 134. Anauxiliary passageway 168 communicates the fluid between the firstauxiliary port 166 and the second main passageway 164 and which isgenerally formed along the longitudinal axis of the elongated manifoldblock 134. The auxiliary passageway 168 can be formed by means of a bore170 made in the second end 138 of the manifold block 134 and after theauxiliary passageway 168 has been formed, the bore 170 is simply pluggedat that second end 138 so that the bore 170 no longer exists in theouter surface of the second end 138. Thus the bleed down valve 130 canbe readily and conveniently affixed into the first auxiliary port 166 ofthe second end 138 of the manifold block 134.

A second auxiliary port 172 is also provided in the second fluidcommunication system and opens outwardly into the front surface 140 ofthe manifold block 134. That second auxiliary port 172 is preferably a ¼inch female pipe thread and into which is affixed the pressure feedbacksensor 132 easily and conveniently and communicates with the auxiliarypassageway 168 of the manifold block 134 and associated with the secondfluid communication system.

As can now be seen, the first fluid communication system that is locatedat the first end 136 of the manifold block 134 and the second fluidcommunication system that is formed in the second end 138 of themanifold block 134 are separate and fluidly isolated systems, that is,there is no fluid communication between the first and second fluidcommunication systems, since any such communication is blocked by thesolid material of the manifold block 134 itself.

Turning now to FIG. 6, there is shown a side cross sectional view takenalong the line 6-6 of FIG. 5. In FIG. 6, there can be seen the presentmanifold 110 comprised of the unitary manifold block 134 having formedtherein the first fluid communication system comprising a first maininlet port 148 that receives the compressed air from oil separator 70(FIG. 4) and a first main outlet port 150 that discharges thatcompressed air to the coalescing filter 72 and is, therefore, connectedto the first fluid conduit 114. As has been noted, both the first maininlet port 148 and the first main outlet port 150 are threaded and arepreferably both ¾ inch pipe thread female connections. As also seen, thefirst auxiliary port 154 is formed in the first end 136 of the unitarymanifold block 134 and is preferably a ½ inch pipe thread fitting. Thefurther second and third auxiliary ports 156, 158, are both formed inthe front surface 140 of the manifold block 134 are shown and which arepreferably ⅛ inch pipe thread fittings.

In the second fluid communication system, located at the second end 138of the manifold block 134, there is formed the second main inlet port160 and the second main outlet port 162 that are coaxially formedtherein and which are, as explained, preferable ¾ inch pipe threadfittings. The bore 170 is also seen to be plugged such that there is nocommunication with the second end 138 to the external environment. Thefirst auxiliary port 166 and second auxiliary port 172 and also formed,respectively, in the bottom surface 146 and the front surface 140 andthe auxiliary passageway 168 communicates with the second mainpassageway 164 intermediate the second main inlet port 160 and thesecond main outlet port 162.

Turning now to FIG. 7, there is shown an end cross sectional view takenalong the line 7-7- of FIG. 6 and illustrating the first main inlet port150 as well as the second auxiliary port 156 that are oriented at about90 degrees with respect to each other.

In FIG. 8, there is shown an end cross-sectional view taken along theline 8-8 of FIG. 6 and illustrating the first main outlet port 150oriented generally at 90 degrees to the first main inlet port 148 (FIG.7) and the third auxiliary port 158 that extends outwardly coaxiallywith the first main outlet port 150.

In FIG. 9, there is an end cross sectional view taken along the line 9-9of FIG. 6 and showing the second auxiliary port 172 of the second fluidcommunication system in the second end 138 of the manifold block 134 aswell as the auxiliary passageway 168 formed therein. The secondauxiliary port 172 is formed as a ⅛ inch pipe thread fitting.

Turning now to FIG. 10, there is shown a schematic view of thecompressor air and oil routing system 174 utilizing the manifold 110constructed in accordance with the present invention. The compressorsystem 174 includes an air filter 176 that directs ambient air to aninlet control valve 178. Air pressure along line 180 controls the inletcontrol valve 178, which regulates air flow into the air compressor 68of FIG. 2. The air compressor 68 provides a compressed air/oil mixturealong line 182 to the oil separator 70. A high temperature switch 184monitors the temperature of the air/oil mixture and is configured toopen a contact (not shown) to disable the magnetic clutch assembly 107of FIG. 3 if the temperature exceeds a predetermined limit. Afterpassing through the oil separator 70, oil exits the oil separator 70 andenters a cooling system that includes a thermostat 186 and a radiator188. A manually controlled drain valve 190 is supplied to drain oil fromthe oil separator 70. The radiator 188 acts as a dual purpose radiatorhaving two cooling chambers. One of the two chambers cools compressoroil and the other chamber cools engine coolant by circulating engine oiltherethrough. Collectively, the oil separator 70, first particle filter74, thermostat 186, and radiator 188 form a compressor oil coolerassembly capable of reducing the temperature of the filtered oil thatreturns to the air compressor 68 along line 192. An oil fill 189 is alsoprovided in-line between the radiator and the thermostat.

The thermostat 186 includes a control valve that directs oil to eitherthe radiator 188 or the first particle filter 74. When oil is selectedby the control valve to pass through the radiator 188, it also passesthrough the first particle filter 74 after flowing though the radiator188 and oil fill 189. After passing through the first particle filter74, the oil enters the air compressor 68. The air, including a smallamount of remaining oil mist, exiting from the oil separator 70 flowsthrough a system that includes the distribution manifold 110 of thepresent invention. A safety valve 124 is provided to limit the pressurein line 194. Air pressure gauge 193 is provided to monitor line 194. Theminimum pressure switch 128 is also connected to line 194 to preventrestart of the compressor 68 until pressure in the manifold 110 hasreached a pre-set low value.

After entering the manifold 110, the air/oil mixture from line 194 flowsthrough the coalescing filter 72. Oil is routed along line 196 back tothe air compressor 68 through a check valve, orifice, and strainerassembly 197. Air exiting from the coalescing filter 72 is delivered toa minimum pressure valve 120 by line 204. If the pressure along line 204is sufficient, air will pass through the minimum pressure valve 120 tothe shut-off valve 54 of FIG. 1, which provides compressed air forpneumatic operations of the welder combination 10. Using air receivedfrom the coalescing filter 72, a pressure regulator 206 regulates airpressure along control pressure line 180 in conjunction with a bleedorifice 208. Pressure in line 180 controls the position of inlet controlvalve 178. Air can also pass from the coalescing filter 72 into ablow-down valve 210 and exit the compressor system 172 through bleeddown orifice 214. Pilot pressure inline 212 is low during compressoroperation and will rise upon shut down. This pressure rise will openblowdown valve 210 to release the high pressure air from the system 172to the atmosphere through orifice 214 at a controlled rate.

As can therefore be seen, the manifold 110 provides the variousconnections and passageways for the overall compressor air an oilrouting system 174 so that the individual flows of compressed air can bereadily accessed and routed to the necessary components. As also can beseen, the present manifold 110 allows the construction and assembly ofthe present welder combination 10 to be simplified as it providesphysical support as well as proper operational connections for a varietyof system components.

In accordance with one aspect of the present invention, a welder and aircompressor combination includes an air compressor that provides a streamof compressed air containing a quantity of oil. The air containing theoil is directed to an oil separator where the air and the oil areseparated. The separated air is then routed through a manifold that hasa number of different ports and passageways to enable the constructionof the combination by simply attaching fluid conduits and components tothe manifold where the internal passageways and fluidly isolated fluidcommunication systems are formed to carry out the necessary connectionsfor such fluid conduits and components.

The present invention has been described in terms of the preferredembodiment, and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. An air compressor system for providing a stream of compressed airsubstantially free of oil to an end use means, said air compressorsystem comprising: an air compressor for providing a stream ofcompressed air laden with oil; an oil separator having an inlet forreceiving the stream of compressed air laden with oil from said aircompressor and an outlet for discharging air having oil separatedtherefrom; an oil coalescing filter having an inlet for receiving airfrom said oil separator for removing additional oil therefrom and havingan outlet for discharging air substantial free of oil; and a unitarymanifold block having a first fluid communication system comprising afirst main inlet port for receiving the stream of air discharged fromsaid oil separator, a first main outlet port for discharging said streamof air, and a first main passageway formed in said unitary manifoldblock communicating between said first main inlet port and said firstmain outlet port, a first air conduit for communicating said airdischarged from said first main outlet port to said inlet of saidcoalescing filter, a second air conduit for communicating said stream ofair discharged from said outlet of said coalescing filter to a secondfluid communication system formed in said unitary manifold block, saidsecond fluid communication system comprising a second main inlet portfor receiving the stream of air from said second air conduit, a secondmain outlet port formed in said unitary manifold for delivering thestream of air to the end use means, and a second main passageway formedin said unitary manifold block communicating between said second maininlet port and said second main outlet port, said unitary manifoldblocking fluid communication between said first fluid communicationsystem and said second fluid communication system, said unitary manifoldfurther having at least one auxiliary port communicating with one ofsaid first fluid communication system and said second fluidcommunication system and wherein said at least one auxiliary portcomprises a first auxiliary port formed in said unitary manifold blockin communication with said first fluid communication system and oriented90 degrees with respect to said first main inlet port.
 2. An aircompressor system as defined in claim 1 wherein said elongated manifoldblock has a main longitudinal axis, and wherein said first mainpassageway is formed parallel to the main longitudinal axis of saidunitary manifold block.
 3. An air compressor system as defined in claim1 wherein said at least one auxiliary port comprises at least twoauxiliary ports in communication with said first fluid communicationsystem, wherein one of said at least two auxiliary ports is orientedparallel to the main longitudinal axis of said elongated unitary block.4. An air compressor system as defined in claim 1 wherein said at leastone auxiliary port comprises an auxiliary port in communication withsaid first fluid communication system and orientated at about 90 degreesto said main longitudinal axis of said block.
 5. A welding and aircompressor system on a common frame, comprising: an air compressor forproviding a flow of compressed air for a pneumatic utilization device;means for generating an arc welding current; means for driving both theair compressor and the means for generating an arc welding current; amanifold for making fluid connections in the welding and air compressorsystem, said manifold being elongated, fixed in a position with respectto the common frame of the welding and air compressor system, and havingfirst and second ends; a first fluid communication system in said firstend of said manifold and a second fluid communication system in saidsecond end of said manifold, said manifold providing fluid isolationbetween said first fluid communication system and said second fluidcommunication system; said first fluid communication system comprising afirst main inlet port adapted to receive the flow of compressed air fromsaid air compressor, a first main outlet port for discharging that flowof compressed air and a first main passageway within said manifoldcommunicating between said first main inlet port and said first mainoutlet port, at least one auxiliary port formed in said manifold incommunication with the first communication system; and said second fluidcommunication system comprising a second main inlet port adapted toreceive the flow of compressed air after passing through an intermediatecomponent, and a second main outlet port for discharging that flow ofcompressed air to said pneumatic utilization device, and at least onesecond auxiliary port formed in said manifold in communication with saidsecond fluid communication system.
 6. A welding and air compressionsystem as defined in claim 5 wherein said manifold has an elongated,generally rectangular cross section having a front, rear, top and bottomsurfaces and said first main inlet port extends through said bottomsurface and said first main outlet port extends through said rearsurface.
 7. A welding and air compression system as defined in claim 5wherein said at least one first auxiliary port comprises an auxiliaryport extending though said first end of said manifold and orientedgenerally along a longitudinal axis of said elongated manifold.
 8. Awelding and air compression system as defined in claim 6 wherein saidsecond main inlet port and said second main outlet port are generallycoaxial and extend through, respectively, the bottom surface and the topsurface of said manifold.
 9. A welding and air compression system asdefined in claim 6 wherein said at least one first auxiliary portscomprises an auxiliary port extending through said front surface of saidmanifold.
 10. An air compressor apparatus comprising: an air compressor;an oil separator connected to receive a discharge flow from the aircompressor; a manifold having formed therein two fluid communicationsystems internally isolated from one another, the manifold beingconnected to receive a discharge flow from the oil separator and whereinthe fluid communication systems each comprise an inlet port, an outletport, a passageway connecting the inlet and outlet ports, and at leastone auxiliary port; an oil coalescing filter connected between the twofluid communication systems; and wherein the inlet ports of the fluidcommunication systems are positioned parallel to one another.
 11. Theapparatus of claim 10 wherein the auxiliary ports are of a smallerdiameter than the inlet ports.
 12. The apparatus of claim 10 wherein theinlet port, outlet port, and connecting passage therebetween of one ofthe fluid communication systems are coaxially formed in the manifold.13. The apparatus of claim 10 further comprising a total of fiveauxiliary ports, each in communication with one of the fluidcommunication systems.
 14. The apparatus of claim 10 wherein themanifold is comprised of a unitary elongated block having a mainlongitudinal axis, and wherein a main connecting passageway of one ofthe fluid communication systems is formed parallel to the mainlongitudinal axis of the manifold.
 15. The apparatus of claim 10 whereinthe oil coalescing filter, being disposed outside the manifold, isconnected between an outlet port of one of the fluid communicationsystems and an inlet port of the other fluid communication system.